Pile weatherstripping manufacturing apparatus and method

ABSTRACT

Pile weatherstripping having an integral fin is made by wrapping a fin material around a traveling mandrel or band, winding pile material around the fin material and the band, attaching a pair of backer elements to the pile material along opposite edges of the band, and then cutting the fin material and the pile material to produce simultaneously two pile weatherstrips. Stationary and traveling elements may be employed to facilitate cutting and produce fin above the pile weatherstrips.

FIELD OF THE INVENTION

The present invention relates generally to the manufacture of pile weatherstripping and, more specifically, to apparatus for and methods of manufacturing pile weatherstripping having an integral fin.

BACKGROUND OF THE INVENTION

Pile weatherstripping is in widespread use in both the automotive and building products industries. Weatherstrip of this type originally was made by forming strips of pile on a backing sheet, either by weaving or by flocking, then applying a resin on the reverse side of the backing sheet, and then slitting the backing sheet between the strips of pile. The resin was typically applied in liquid form, and cooled or cured before the slitting step. If desired, supplemental material, such as fins, may be included and ultrasonically welded in place to form combination weatherstrips.

Advancements in the art resulted in making pile type weatherstripping without first weaving a pile fabric, without flocking, and without the application of a liquid resin. Briefly, yarn that forms the pile is wound on a traveling mandrel or band and is welded while still on the mandrel to backing strips, typically two in number, aligned on opposite sides of the mandrel. The yarn is then parted at locations interdisposed between the backing strips to form two continuous pile weatherstrips. If desired, supplemental material, such as fins, may be included and welded in place simultaneously with the backing strips to form combination weatherstrips. See, for example, U.S. Pat. No. 3,677,851 to Kayser, U.S. Pat. No. 4,148,953 to Horton, U.S. Pat. No. 4,302,494 to Horton, U.S. Pat. No. 5,338,382 to Johnson et al., U.S. Pat. No. 5,807,451 to Johnson, and U.S. Pat. No. 5,817,390 to Johnson, the disclosures of which are incorporated by reference herein in their entirety.

The commercial market for integral fin pile weatherstripping generally desires that the fin extend above the cut pile. Therefore, there exists a need in the art to produce fin above the pile weatherstripping in a continuous, efficient, high yield process, without having to undertake additional steps, such as coining the fin material in an attempt to control registration of the fin material on the band and, ultimately, height of the fin relative to the cut pile.

SUMMARY OF THE INVENTION

According to one aspect, the invention concerns a method of continuously manufacturing a pile weatherstrip having an integral fin. The method includes the steps of wrapping a fin material at least partially around a traveling band while keeping the fin material spaced from the band at at least one location using a stationary element. Thereafter, the method includes winding a pile material around the fin material and the band, attaching a backer to the pile, and cutting the fin material and the pile material to produce the integral fin pile weatherstrip.

In one embodiment, the stationary element can be at least one wire, generally aligned with a centerline of the band. The method can further entail spacing the pile material from the band at at least one location prior to cutting the pile material. This spacing may occur initially at the winding step. In certain embodiments, the pile material is spaced from the band using a traveling element, such as at least one wire. In a particular embodiment, the traveling element is three wires, wherein two wires are disposed proximate a first side of the band and one wire is disposed proximate a second side of the band. In this embodiment, the fin material is disposed between the two wires and the band. Spacing between the two wires may converge in a downstream direction, from the winding step to the cutting step. The one wire disposed proximate the second side of the band can be offset from the centerline of the band.

In one embodiment, the step of attaching the backer can employ ultrasonic welding. If desired, the backer can be separate first and second backer elements, such that two integral fin pile weatherstrips result when the fin material and the pile material are cut. The method may include the step of employing a second stationary element, disposed between the fin material and the band, to facilitate the cutting step.

According to other aspects, the invention is also drawn to a pile weatherstrip having an integral fin manufactured in accordance with the foregoing methods, as well as a machine for manufacturing a pile weatherstrip having an integral fin. In general, the machine includes a traveling band and a guide for wrapping a fin material at least partially around the band, the fin material being spaced from the band at at least one location using a stationary element. A winding station is provided for winding a pile material around the fin material and the band. Downstream thereof is an attachment station for attaching a backer to the pile and a slitter station for cutting the fin material and the pile material to produce the integral fin pile weatherstrip.

In one embodiment, the stationary element can be at least one wire that may be generally aligned with a centerline of the band. The machine may also include a traveling element for spacing the pile material from the band at at least one location prior to cutting the pile material. In one embodiment, the pile material is spaced from the band at the winding station and the traveling element can be at least one wire. In a particular embodiment, the traveling element is three wires, wherein two wires are disposed proximate a first side of the band and one wire is disposed proximate a second side of the band. In this embodiment, the fin material is disposed between the two wires and the band and spacing between the two wires converges in a downstream direction, from the winding station to the slitter station. The one wire disposed proximate the second side of the band is offset from the centerline of the band.

The attachment station may be an ultrasonic welder. If desired, the backer can be first and second backer elements, such that two integral fin pile weatherstrips result when the fin material and the pile material are cut. A second stationary element may be disposed between the fin material and the band to facilitate cutting the fin material and the pile material at the slitter station.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, in accordance with preferred and exemplary embodiments, together with further advantages thereof, is more particularly described in the following detailed description, taken in conjunction with the accompanying drawings, in which:

FIG. 1A is a schematic side view of one embodiment of a machine for manufacturing a pile weatherstrip having an integral fin in accordance with the invention;

FIG. 1B is a schematic plan view of the machine of FIG. 1A;

FIG. 2A is a schematic front view of an alignment block, including a portion of the stationary element, disposed upstream of the fin wrapping guide in accordance with one embodiment of the invention;

FIG. 2B is a schematic front view, downstream of FIG. 2A, of the fin wrapping guide and the stationary element in accordance with one embodiment of the invention;

FIG. 2C is a schematic front view, downstream of FIG. 2B, of the fin wrapping guide and the stationary element in accordance with one embodiment of the invention;

FIG. 3 is a schematic cross-sectional view of a backer element in accordance with one embodiment of the invention;

FIG. 4 is a schematic plan view of the backer attachment station in accordance with one embodiment of the invention;

FIG. 5 is a schematic perspective side view of the second stationary element in accordance with one embodiment of the invention;

FIG. 6 is a flowchart of the process steps in accordance with one method of the invention;

FIGS. 7A–7F are schematic cross-sectional views of the band at various stations on the machine showing the stages of manufacture of the pile weatherstrip; and

FIG. 8 is a schematic cross-sectional view of a fin above the pile weatherstrip manufactured in accordance with one embodiment of the invention.

DETAILED DESCRIPTION

The presently preferred and alternative embodiments of the invention, including the best mode for practicing the invention known to the inventors at this time, are now described in detail in connection with the accompanying drawings.

Briefly, FIGS. 1A–1B are schematic side and plan views of one embodiment of a machine 10 for manufacturing a pile weatherstrip having an integral fin in accordance with the invention. In accordance with the flowchart of FIG. 6, one method of the invention begins with the wrapping of a fin material 12 at least partially around a continuous or endless, traveling mandrel or band 14 using a wrapping guide 22, as best seen in FIGS. 2B–2C. See also FIGS. 7A–7F, which are schematic cross-sectional views of the band 14 at various stations on the machine showing the stages of manufacture of the fin above the pile weatherstrip 20 depicted in FIG. 8. Note that the fin material 12 is shown as being relatively thick, to facilitate depiction of the manufacturing method. In reality, the fin material 12 can be relatively thin, for example, on the order of about 0.003 inches to about 0.012 inches in thickness.

In one embodiment, as shown in FIGS. 1A–1B, the fin material 12 is drawn from a spool 13 and is spaced from the band 14 at at least one location using a stationary element 16, such as a wire. See FIG. 7B. The stationary element 16 is generally aligned with a centerline of the band 14 and may be anchored in an alignment block 21, that generally aligns and centers the fin material 12 vertically over the band 14. See FIG. 2A. The stationary element 16, alternatively, may be formed integrally with the alignment block 21. The stationary element 16 causes excess fin material 12 to be disposed on one side of the band 14, the excess fin material 12 ultimately extending above the pile material once both are cut to form the finished weatherstrip 20, as depicted in FIG. 2B. Depending on the size of the stationary element 16, the excess fin material 12 in the finished weatherstrip 20 can extend above the pile material from about 0.001 inches to about 0.1 inches, or more. In general, the commercial market desires that the excess fin material 12 in the finished weatherstrip 20 extend above the pile material from about 0.01 inches to about 0.02 inches.

The fin material 12 is wrapped around the band 14 by any suitable structure. For example, as depicted in FIG. 2B, the wrapping guide 22 may include a stationary skid plate 22 a, that supports the traveling band 14, and a rotating grooved roller 22 b that, in combination, form a nip for passage therethrough of the band 14 and fin material 12. This portion of the wrapping guide 22 directs the edges of the fin material 12 downward, along the edges of the band 14. As depicted in FIG. 2C, another portion of the wrapping guide 22, directly downstream, completes wrapping of the fin material 12 on the band 14, by passing the fin material 12, the band 14, the stationary element 16, and a lower traveling wire 18 c through a two piece split block 22 c. A converging, tapered tunnel 25, having a generally inverted triangular shape, that is formed in the split block 22 c wraps the edges of the fin material 12 up against a bottom surface of the band 14.

As the fin material 12 is wrapped around and spaced from the band 14, a traveling element 18 is biased against the band 14. In one embodiment, the traveling element 18 includes three continuous wires 18 a, 18 b, and 18 c that travel with the band 14. As best seen in FIGS. 2B, 2C, and 7C, two wires 18 a, 18 b are disposed proximate a first side of the band 14, initially near the edges thereof, on the same side as the excess fin material 12 and stationary element 16. Two circumferential grooves 23 a, 23 b formed in the roller 22 b maintain the two wires 18 a, 18 b in proper alignment and registration with the band 14. The third, lower traveling wire 18 c is disposed proximate a second side of the band 14 and is offset from the centerline of the band 14. A linear groove 23 c formed in the skid plate 22 a maintains the wire 18 c in proper alignment and registration with the band 14. Another circumferential groove 23 d is provided in the roller 22 b to provide clearance for the stationary element 16. Downstream, a pair of grooves 23 e, 23 f formed in the top of the split block 22 c finally position the two wires 18 a, 18 b relative to the band 14 prior to passage of the band 14 through a winding station 26. See FIGS. 1A–1B.

As depicted in FIGS. 7D–7F, the traveling element 18 is used, at least in part, for spacing pile material 24 from the band at at least one location prior to cutting the pile material 24. With the traveling element 18 in place, the band 14 passes through the winding station 26 where the pile material 24 is wrapped around the fin material 12 and the band 14. With reference to FIGS. 1A–1B, the pile material 24 may be in the form of yarn and is drawn from a plurality of cones 28 carried by a revolving spindle 30. In one embodiment, twelve yarn cones 28 are used. The yarn passes through guide apertures in a disk 31 that is also fixed to the spindle 30. As shown, the band 14 may be simply a flat strip of metal or other suitable material, half of the width of which determines the height of the pile of the finished weatherstrip 20. To facilitate manufacture of a uniform pile weatherstrip, it may be desirable to knurl or otherwise roughen slightly the edges of the band 14 so that the pile material 24 wrapped thereon stays in place until attached to a backer 32.

As shown in FIGS 1A–1B, and specifically FIG. 7D, at the winding station 26, the band 14 passes axially through the rotating spindle 30 and receives the pile yarn in a continuous helical wrap. The rotational speed of the spindle 30, the travel speed of the band 14, and the number and type of yarn cones 28 determine the density of the pile in the finished weatherstrip 20. The stationary element 16 terminates at a point just downstream of where the pile material 24 is wrapped around the band 14.

Downstream of the winding station 26, a backer 32 is then mated with an edge of the band 14 at an attachment station 35. As best seen in FIG. 3, the backer 32 includes a groove 37 to receive the edge of the band 14. The backer 32 can be formed by extrusion or any other suitable manufacturing process. In one embodiment, the backer 32 includes separate first and second backer elements 32 a, 32 b mated to opposite edges of the band 14, such that two integral fin pile weatherstrips result when the fin material 12 and the pile material 24 are cut.

As seen in FIG. 1B, the backer elements 32 a, 32 b are unreeled from respective spools 34 a, 34 b and biased into contact with the pile material 24 by suitable guides, such as rotatable disks 33 a, 33 b, along opposite edges of the band 14 synchronously with the travel of the band 14. See FIGS. 4 and 7E. The backer elements 32 a, 32 b are then permanently attached to the pile material 24 at the attachment station 35, for example by being welded to the pile material 24 using an ultrasonic welder 36. Insofar as the backer elements 32 a, 32 b are on opposite edges of the band 14, two ultrasonic welders 36 a, 36 b can be used.

Respective anvils 38 a, 38 b may be mounted in opposition to the ultrasonic welders 36 a, 36 b to support the band 14, prevent deflection thereof under the force applied by the ultrasonic welders 36 a, 36 b, and maintain the backer elements 32 a, 32 b in close contact with respective welders 36 a, 36 b. To minimize friction and resultant drag on the backer elements 32 a, 32 b, the anvils 38 a, 38 b can be bearing mounted rotatable disks, having a suitable circumferential contour to mate with the outer surfaces of the backer elements 32 a, 32 b.

The anvils 38 a, 38 b may be biased into contact with the backer elements 32 a, 32 b by any suitable means, such as pneumatic pistons 40 a, 40 b, the pressure in which may be regulated to provide appropriate force. In welding, it is generally desirable to apply enough energy to impart a set to the pile material 24, conforming the pile material 24 to the shape of the band 14 and grooves 37 formed in each backer 32, so that in the finished weatherstrip 20, the pile material 24 extends generally perpendicular to the backer 32 and does not tend to splay outwardly excessively or lie too flat. As depicted in FIGS. 1B and 4, the pistons 40 a, 40 b are shown in an unpressurized state, such that the anvils 38 a, 38 b are retracted from each backer 32 and the band 14. In operation, during welding, the anvils 38 a, 38 b are biased against each backer 32 and pressure in the pistons 40 a, 40 b can be independently set. Air coolers can also be provided to prevent overheating of the ultrasonic welders 36 a, 36 b.

Following attachment of the backer 32, the pile material 24 and the fin material 12 are parted at points between the backer elements 32 a, 32 b at a slitter station 42 having a pair of circular cutting wheels 44 a, 44 b, and the resulting weatherstrips 20 a, 20 b are delivered to downstream take-up spools or otherwise packaged. A puller may be employed to maintain tension on the weatherstrips 20 a, 20 b as they are produced.

At the slitter station 42, a second stationary element, such as a slitter guide 46 depicted in FIGS. 5 and 7F, may be employed to facilitate cutting of the fin material 12 and the pile material 24. The slitter guide 46 is disposed proximate the band 14 and has a tapered leading edge 48 that rides under the fin material 12. Two longitudinal grooves 50 a, 50 b are formed in the slitter guide 46 along the edges thereof, through which the two upper traveling wires 18 a, 18 b pass, with the excess fin material 12 disposed therebetween. The grooves 50 a, 50 b are initially open at the top and then at the bottom to capture positively the two wires 18 a, 18 b. A third centrally disposed longitudinal clearance groove 50 c is provided, in which the periphery of the upper cutting wheel 44 a passes, to cut simultaneously both the fin material 12 and the pile material 24. In this way, both the fin material 12 and the pile material 24 are cut, without the cutting wheels 44 a, 44 b contacting the band 14. Also, the two upper wires 18 a, 18 b converge in the downstream direction, being relatively widely spaced by the split block 22 c, just prior to entering the winding station 26, and relatively closely spaced by the slitter guide 46, at the slitter station 42. In this manner, the excess fin material 14 is captured and maintained between the two wires 18 a, 18 b, so that it rides up smoothly over the slitter guide 46 and is cut in the center, yielding two substantially dimensionally equivalent weatherstrips 20 a, 20 b. See FIG. 1B.

The pile material 24 and the backer elements 32 a, 32 b are preferably of the same, or at least of compatible, polymers selected in view of the welding requirements. In some cases, polymers of different respective compositions can be welded together satisfactorily. Typical thermoplastic compositions for both the pile material 24 and the backer elements 32 a, 32 b include nylon, polyolefin, polyester, polyethylene, and polypropylene. Thermoplastic elastomers, which are a blend of a polymer resin and a natural or synthetic rubber, can also be used. The fin material 12 should also be made of a compatible polymer. In one embodiment, the pile material 24 and backer elements 32 a, 32 b are polypropylene, and the fin material 12 is be an embossed non-woven polypropylene fabric, adhered to a thin polypropylene film substrate. In various embodiments, suitable compositions for the pile material 24 and the backer elements 32 a, 32 b may be 12-melt yarn, Adsyl, Moplen, Polybutene-1, 1150 denier homo-polymer polypropylene, Hifax, Adflex, PP P4G4K-038, Hostacom, PMZ-080, Adstif, TP-1300-HC, Lupolex, PP-37-DC-01, 7823 Poly, P10-3045, SD-613, HNZ-020, P9HIA029X, 18507A, Valtec, Lupolen, 14S05A, Pro-fax, P6M2Z-080, PE LLD 03040, EFI natural yarn, and American yarn, including equivalents and blends, and various combinations and permutations thereof. Suppliers for these materials include Basell Polyolefins Company N.V., Phillips Sumika Polypropylene Company, and Xamax Industries, Inc.

In any event, the fin material 12, the pile material 24, and the backer elements 32 a, 32 b are all welded in the single-pass welding steps depicted and described. With the inclusion of the fin material 12 in the construction, greater welding energy than would otherwise be required should be applied, to impart the desired set to the fin material 12, as well as to the pile material 24.

The invention also contemplates making a single weatherstrip by simply eliminating one of the backer elements 32 a, 32 b and parting the pile material 24 at a single point opposite from the remaining backing strip. The double backer arrangement depicted and described is beneficial, however, because of its greater efficiency. The practice of the invention enables a substantial reduction in cost relative to the heretofore conventional woven method of making fin above the pile weatherstripping. Forming the pile by winding is quicker and cheaper than weaving or flocking, and heavier gauge yarn, or even roving may be used. Welding of the backer elements is also advantageous in that it avoids the need to handle a liquid resin and a subsequent welding step to insert the fin material is not required. The practice of the invention also enables a substantial reduction in cost relative to the heretofore conventional method of making wound fin above the pile weatherstripping with a pair of separate coined fins. Forming the pair of pile weatherstrips by cutting the pile material and the fin material is less complex, less expensive, and more reliable than having to provide equipment to accurately coin and correctly register a pair of fins on the band.

The traveling band 14 is of generally uniform cross-sectional shape and size throughout its length, thus insuring that the pile material 24 is firmly positioned and properly tensioned for the welding operation. The only potential limitation on the speed of production appears at present to lie in the winding step. Centrifugal force limits the rotational speed of the spindle 30, but the supports for the yarn cones 28 can be made strong enough to sustain fairly high speed winding, and experience indicates that overall production time in the practice of the invention is significantly shorter than the time heretofore required to convert yarn and backing strips into woven pile weatherstripping. As with any high speed rotating spindle, care should be taken in the design of the machine frame to minimize vibratory resonances, for example by appropriate sizing of the mass of the frame or the addition of dampers.

The machine 10 further includes suitable motors, drive transmission components, sensors, and a controller to coordinate the operation of the machine 10, as will be apparent to those skilled in the art. The various stations of the machine 10, as well as guides and roller supports for the band between stations, may also be advantageously made adjustable in three orthogonal directions, to facilitate setup of the machine for various width bands, as well as to permit compensation for wear over time. System diagnostics, sensor-based fault detection, feedback control, and other troubleshooting tools consistent with robust production manufacturing systems may also be advantageously employed to ensure high quality process yields and minimal downtime.

While there have been described herein what are to be considered exemplary and preferred embodiments of the present invention, other modifications of the invention will become apparent to those skilled in the art from the teachings herein. All variants, modifications, and alternative embodiments that will occur to the skilled person are considered to be within the scope of the invention. For example, the fin material could be wound on the band helically and cut both above and below the band, as the pile material is cut. Additionally or alternatively, the first and second stationary elements can be any cross-sectional shape and can be multiple elements, such as two or more wires or leading edges. Also, the second stationary element grooves can be initially open at the bottom and then at the top, or only open at the bottom or the top, and respective lengths can vary. Further, the traveling element can be more or fewer than three wires. The lower traveling wire need not be offset from the centerline of the band and the first and second stationary elements need not be centered. Similarly, the cutting wheels need not be centered or aligned. All of these components may be arranged, as desired, to produce pile weatherstrips having nonuniform configurations, such as high pile along one side and low pile along the other. The two pile weatherstrips produced simultaneously also need not be substantially geometrically identical.

It is therefore desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention. Accordingly, what is desired to be secured by Letters Patent is the invention as defined and differentiated in the following claims, including all equivalents. 

1. A method of continuously manufacturing a pile weatherstrip having an integral fin, the method comprising the steps of: wrapping a fin material around a traveling band so as to provide excess fin material proximate at least one side of the band; winding a pile material around the fin material and the band, such that the excess fin material is relative to the pile material proximate the at least one side of the traveling band; attaching a backer to the pile material; and cutting the fin material and the pile material to produce the pile weatherstrip.
 2. The method of claim 1, wherein the wrapping step comprises wrapping the fin material at least partially around the traveling band and spaced from the band at at least one location using a stationary element.
 3. The method of claim 2, wherein the stationary element is generally aligned with a centerline of the band.
 4. The method of claim 1 further comprising the step of spacing the pile material from the band at at least one location prior to cutting the pile material.
 5. The method of claim 4, wherein the pile material is spaced from the band at the winding step.
 6. The method of claim 4, wherein the pile material is spaced from the band using a traveling element.
 7. The method of claim 6, wherein the traveling element comprises at least one wire.
 8. The method of claim 7, wherein the traveling element comprises three wires.
 9. The method of claim 8, wherein two wires are disposed proximate a first side of the band and one wire is disposed proximate a second side of the band.
 10. The method of claim 9, wherein the fin material is disposed between the two wires and the band.
 11. The method of claim 9, wherein spacing between the two wires converges in a downstream direction, from the winding step to the cutting step.
 12. The method of claim 9, wherein the one wire is offset from a centerline of the band.
 13. The method of claim 1, wherein the attaching step comprises ultrasonic welding.
 14. The method of claim 1, wherein the backer comprises a first backer element and a second backer element, such that two integral fin pile weatherstrips result when the fin material and the pile material are cut.
 15. The method of claim 14, wherein the cut fin material extends above the pile material of at least one of the two integral fin pile weatherstrips.
 16. The method of claim 14, wherein the cut fin material extends above the pile material of the two integral fin pile weatherstrips.
 17. The method of claim 1 further comprising the step of employing a stationary element disposed between the fin material and the band to facilitate the cutting step.
 18. The method of claim 1, wherein the cutting step produces the pile weatherstrip wherein the cut fin material extends above the pile material.
 19. The method of claim 1, wherein the cutting step comprises cutting the pile material at a location opposite the backer.
 20. The method of claim 1, wherein the cutting step is performed by at least one cutting wheel located on at least one side of the traveling band.
 21. The method of claim 1, wherein the wrapping step comprises wrapping a single fin material around the traveling band. 